Method of weaving frieze pile fabrics



Oct. 12, 1937; A. w. DROBILE 2,095,332 METHOD WEAVING FRIEZE FILE FABRICS Filed March 14, 1935 2 Sheets-Shed 1 INVENTOR.

ATTORNEY.

Patented Oct. 12, 1937 UNITED srA'r i:

mn'rnon or WEAVING rim-:zn run .rsmucs Allgrt W. Drobile, Wayne, Pmassignor to Collins Ailnnan Corporation, Philadelphia, Pa., a

corporation of Delaware Application March 14, 1935, Serial No. 10,978

4 Claims. (Cl. 139-21) My invention is a method of simultaneously weaving in superposed relation a plurality of frieze pile fabrics having of different lengths woven face toface on a dou- 5 ble shuttle loom having a pair of sets of sheddedpile'gauges extending warpwise.

In accordance with my invention, the shuttles of a, double shuttle loom are picked simultaneously tolay complementary pairs of weft threads.

and the sets of gauges, and the warp threads are 'so shedded that the picks laid by the upper shuttle form a new of wefts above the top set of gauges and a row of wefts between the gauges and the picks laid by the bottom shuttle form arow of 'wefts between the gaugesand a row of wefts below the bottom gauges, the gauges being shed- 'ded togetheror toward one another when .the wefts are being laid above and below the gauges and the sets of gauges being shedded'apart when 2 the rows of wefts are being laid between the gauges. The sets of gauges operate on the mid- .closing principle, that is they have two positions,

a horizontal position and a deflected position.

t The upper set of gauges is moved upwardly and. 25 the lower set downwardly from their horizontal positions. The warp threads are so shedded during the laying ofthe picks that most of the wefts in the row above the gauges are interlaced with the ground warp threads to form the ground 30 of the upper fabric and to secure in such ground 1 pile warp threads looped over the upper row of wefts between the gauges to form short loops on the upper fabric, and to also secure to the upper ground pile warp threads which are looped over 35 certain of the wefts between the lower gauges.

and the lower ground to form long pile loops on the upper ground. Similarly, ground warps interlace the wefts below the gauges, excepting those looped within long loops of the upper fab- 40 ric, to form. the ground of the lower fabric and secure thereto pile warp threads looped over the "remaining or lower wefts between the gauges and also secured to the lower ground the long loops formed by pile warp threads passing over the a 45 wefts above the top gauges which are-not interlaced with the upper. ground.

1 Preferably the rows of loops of different heights on each fabric adjoin one another in regular repeat or in pattern formation and the pile loops 50 may be united with the ground in a loose pile of V-tuft construction, or the pile loops-may be united with the ground in a tight pile of W-tuft construction. Where the W-tuft construction is used, the intermediate portion or knee of the 55 W-tuft may pass over one ground weft only orl self-separating loops.

' mechanisms.

may pass over two or more grou d wefts. In any of these types of construction, the ground may be composed of two series of tight warp threads with uniform take-up .or may be composed of one series of tight warps and one series of slack -5. warps so as to vary the -appearance and erectness of the pile loops. The low loops and high loops on each fabric may be formed from the same series of pile warp threads or-may be formed from two different series of .pile. warp threads, one- 10 forming the low loops and t 'e other forming the high loops, which may be le off bytwo delivery Fabrics having a surface pattern' or figure composed 'of high and low loops according to a pre- 15 arranged design may be woven in accordance with my method by so shedding the pile warps that a high pile loop or a low pile loop, or both of them, can beforme'd on any ground weft or weits, as required or .desired for'the production of the desired design drflgure.

During the weaving of thefabrics and at the fell of the cloths where the wefts are beaten up,

the two fabrics are interlocked due to the interlacing of'the pile yarns" therefor over and between thetwo sets'of shedded warpwise gauges, which act as retaining or coupling pins'and coact with the. let-off mechanism to regulate the length of the long pile loops. After the fabrics move down toward the take-off rollers, the wefts slide off of the ends of the gauges to permit the self-separating of the loops andthe separation of the fabrics by merely cutting the few connecting threadsat the selvag'es.

The characteristic features and advantages of my improvements will further appear from the following description and the accompanying drawings in illustration thereof.

In the'drawings,- Fig. 1 is a diagrammatic fragmentary view illustrating the weaving of super- 40 posed pile fabrics in accordance with my invention and the separation of the pile loops thereof as they move down off the ends of the wa'rpwise extending gauges; Fig. 2 is a diagrammatic'fragmentary view illustrating the weaving. of super posed pile fabricsin modified form in accordance with my invention and the, separation of the pile v loops thereof as they move down off the ends of the warpwise extending gauges; Fig. 3.is a fragmentary diagrammatic view illustrating the weaving of superposed-pile fabrics of a further modified form in accordance with my invention and the separation of the pile loops thereof as they move down off theends of thewarpwiseextending gauges; Fig. 4 is adiagra'mmatic 'fragmentary view illustrating the weaving of superposed pile fabrics with tight and slack ground warp threads in accordance with my invention and the separation of the-pile loops thereof as they move down off the ends of the warpwise ex-. tending gauges; Fig. 5 is a diagrammatic fragmentary view illustrating the weaving of superposed fabrics with high and low loops over the same ground weft; Fig. 6 is a fragmentary diagrammatic view illustrating the fabric woven in accordance with Fig. 5 after the removal of the pile supporting wefts; Fig. 7 is a drawing-in diagram for drawing in the warps for weaving the fabric illustrated in Fig. 5, and Fig. 8 is a diagram illustrating the shedding of the warps during the weaving of a repeat of the fabric illustrated in Fig. 5.

In the practice of my invention as illustrated in Fig. 1, a double shuttle loom having the simultaneously operable shuttles X and X and a usual reed Y is provided with warpwise extending gauge wires A, A which may have their rear ends connected with a cross-bar Z.

The gauges A and A preferably consist of round resilient wires which pass through and are shedded by heddles in suitable heddle frames (not shown) and pass through the reed spaces between the reed dents and slightly past the fell of the fabric being woven.

-The loomis also provided with suitable heddle frames and harness mechanism for shedding in desired sequence the pile warp P and the ground warps B and 1B for forming the upper fabric and the pile warp P and the ground warps B and B for forming the bottom fabric.-

The cycle of weaving a repeat of the fabric may be considered as starting with the simultaneous laying of the wefts l a and lb which are laid by the shuttles X and X respectively above the set of gauges A and below the set of gauges A while the gauges are both shedded toward one another by the heddle and harness mechanism of the loom. The weft la is laid between the ground warp threads B and the ground warp threads B and the pile warp threads P and forms a ground weft in the upper fabric and secures thereto the pile warp threads P The Cir weft lb is laid between the ground warp threads B and the ground warp threads B and pile warp threads P and forms a ground weft in the lower fabric and secures therein the pile warp P After the beating up of the wefts la and lb by the lay and the crossing of the respective pairs of ground warp threads, the shuttles X and X lay. the respective wefts 2a and 2b between the gauges A, A while the gauges are shedded apart by a heddle and harness mechanism to permit the passage of the shuttles. During the laying of the picks 2a and 2b the pile warp threads P and the pile warp threads P are shedded to the middle pile position and the ground warp threads of the upper fabric are shedded above the shuttle X and the ground warp threads of the upper fabric are shedded above the shuttle X and the ground warp threads of the lower fabric are shedded below the shuttle X. Consequently, on the next shedding of the pile warp threads P and P, the weft 2a is drawn against the gauges A and a short loop is formed on the upper fabric and the weft 2b is drawn against the gauges A and a short loop is formed on. the bottom fabric.-

. Before the pile warps P and P are shedded, however, to form the short loops, the gauges A, A

are shedded toward one another to permit the laying of the weft 3a by the shuttle X above the gauges A and to permit the laying of the weft 3b by the shuttle X below the gauges A. The weft 3a is laid between the appropriately shedded ground warp threads B and B to form merely a ground weft in the upper fabric. The weft 3b is laid between the appropriately shedded ground warp threads B and I3 and forms merely a ground 'weft in the lower fabric.' The normal operation of the loom will beat up the wefts 3a, 3b, into substantial vertical alignment with 2a, 2b respectively.

While the gauges A and'A are still shedded toward one another the shuttle X lays a further weft laabove the gauges A and the shuttle X lays a further weft 4b below the gauges A.

, During the laying of the weft 4a the ground warp threads B and the pile warp threads P are shedded in the upper positions in the uppershed and the ground warp thread B is shedded in the lower position of the upper shed. Consequently the weft 4a forms a ground weft in the upper fabric and secures therein the pile warp P to complete the formation of the short loops over the weft 2a. During the laying of the weft 4b the ground warp threads B are shedded in the upper position of the bottom shed and the ground warp threads B and pile warp threads P are shedded in the lower positions in the bottom shed so that the weft 4b forms a ground weft in the bottom fabric and secures therein the pile warp threads P to complete the formation of short loops over the weft 2b.

During the laying of the wefts 5a and 5b by the shuttles X and X, the set of gauges A are in their middle positionso that the weft 5a is laid above such gauges and between the ground warp threads B and B to form a ground weft in the upper fabric. The set of gauges A, however, are shedded to their upper or horizontal position so that the weft 5b is laid below the gauges A but above the plane of the warps of the bottom shed and above the pile warp threads P which are shedded to their lowermost position. Consequently the weft 5b is not engaged in the bottom ground but is drawn against the gauges A to form a support for a row of long loops on the top fabric.

During the laying of the wefts 6a and 6b respectively by the shuttles X and X, the set of gauges A is shedded downwardly to a lower or horizontal position and the warps of the upper fabric and the pile warp threads P of the lower fabric are all shedded to an upper position so that the weft 6a is not engaged with the warps of the upper fabric but lie beneath the pile warp threads P of the lower fabric and is drawn thereby-against the gauges A to form a long loop on the lower fabric. The set of gauges A is shedded to its middle position so that the weft 6b is laid beneath the same and within the shed formed by the spaced warp threads B and B and forms a ground weft in the lower fabric.

By the continued repetition of the foregoing cycle, there are produced upper and lower fabrics each having loops of unequal length which slide off the ends of the gauges A, A and permit the self-separation of the fabrics. Such fabrics may be expeditiously woven and have well covered grounds since there is a loop supported by a supplementary weft over every other ground weft of the fabric. 1

When it is desired to interlace the pile warps in the ground with a w interlacing, instead of I the V interlacing shown in Fig. l, this may be done as illustrated in Fig. .2 by providing one set of warp ends for each fabric to form the short loops thereon and a second set of warp ends for each fabric to form the long loops thereon.

In weaving such a fabric,-as illustrated in Fig. 2, the picks la, lb, 2a, 2b, 3a, 31), la, 4b, 5a, 5b, Ba and 6b are laid in'the same way as in Fig. 1

and the ground warps B B B and B are interlaced with the groundwefts in'the same way as in Fig. l. The pile warp ends P and P are shedded to form short loops over the wefts 2a and 2b of the upper and lower fabrics respectively, but instead of the pile warp ends P being looped over the wefts 5b, such ends are drawn into the upper ground and interlaced tightly I therein over the ground weft 5a. Similarly the the respective grounds by a ground thereof.

disposed between ground weft as shown wefts. wand 81) are and 8a, and over the weft pile warp ends P instead of being' looped over the supplementary weft 6a, are interlaced tightly in the ground and over the ground wefts 6b. Additional sets of pile warp ends P and P are provided to form long loops respectively on the, upper and lower fabric. The pile warp ends P are first interlaced with a W interlacing around the wefts Ia, 3a and 4a and are then looped over the weft 56 between the gauges A and the ground of the bottom. fabric and then returned to the top vfabric'for a further W interlacing with the The pile warp ends-P are first engaged by a W ricground and are then looped over the weft 6a the gauges A and the ground of the upper fabric before being returned to the lower ground for a further w interlacing therewith. I

When the fabric so woven is moved down off the ends of the gauges A and A, the fabrics automatically separate and there is thus provided two fabrics each having alternating rows of short pile loops and long pile loops spaced from one another by but a single ground we t and with both the long pile loops and the sho t pile loops held in Where close coverage of the ground by the 'loops is not requisite. the intermediate portions of the W interlacing in the ground of'the pile warps may be floated over a plurality of ground wefts, as shown in Fig. 3, instead of over a single in Fig. 2. With this type of construction, as shown in Fig. 3, additional wefts la and 8a are inserted. in the top fabric on opposite sides of the weft 5a and additional inserted in the ground of the bottom fabric on the opposite sides of the weft 6b. Pile warps P forming the short loops on the upper fabric, are interlaced in the ground thereof over the weft 4a,. under the wefts 1a, 50., la before being looped over the weft 2a. Similarly the pile warp ends P forming the short pile loops on the lower fabric, are interlaced in the ground thereof under the weft 4b, over the wefts lb, 6b, 8b and under the weft ib'before being looped over the weft 2b thereof. The pile warp ends P forming on the upper fabric loops supported by the supplethereof over the weft 8a, under the wefts la, 3a and 4a and over the weft la. The pile warp ends P kiforming on thelower ground the long pile loops supported by the supplementary wefts 6a, are interlaced in the lower ground under the wefts 8a, over the wefts 1b, 3b, 4b and ,under the weft lb. I

Insteadof the ground warps B B B and B being under equal tension, as in Figs. 1, '2 and-3,

be placed under tight tension 'warps in the interlacing with the bottom fab- W-type interlacing.

one of the ground warps in the upper ground may and the other ground warp in the under slack tension. Similarly one of the ground lower ground may be placed under tight tension and the other-ground warp in the lower ground placed under slack tension. The application of tight and slack tensions to the respective ground warps of ,the weave shown in Fig. 3 is illustrated in Fig. 4 where the ground warps'B and B are under tight tension and the ground warps l3 and B are under slack tension, thereby shifting the rows of loops closer toward one another.

As illustrated in Figs. 5 to 8 inclusive, fabrics may be woven face to face in. accordance with upper ground may be placed I my invention with, a long loop or a short loop or both over any particular ground weft or wefts of each fabric. In accordance with this modification, a repeat having the foregoing characterthreads B B and under the pile -warps P and P The weft lb is laid in a shed formed by the ground warp threads B and B and above the pile warps P and P Before the laying of the next pair of wefts 2a and 2b, the sheds are changed as shown in Fig.

'7 by shedding the warps so that the weft 2a is laid in the top ground formed by the ground warps 13. B and above both pile warps F 9" and P The weft 2b is laidabove the bottom fabric and beneath the pile warp P "and the gauge 'A. The backing warps and gauges have only two weaving positions.

Before the laying of the next pair of wefts 3a and 3b, the gauges .A and A are shedded so that the weft 3a is laid between the gauges A and the pile warp P and the weft 3b islaid between the gauges A and the pile warp 'P Before the laying of .the next pair of wefts 3a and 4b, the gauges and warps are again shedded so that the weft 4a is laid below the top fabric and between the gauge A and the warp threads.

P and the weft 4b is laid in the ground formed by the ground warps B and B and beneath both i the pile warps P and P As the fabric weaves down toward the take-up rolls, the loops slide off the end of the gauges A and'A' to permit the fabrics to separate from one another, and when the pile supporting wefts are pulled, a high loopand a low loop are left over a ground weft-in each repeat. i

Should it be desired to form a cut and uncut looped fabric from any of the loopedfabrics above" described; the tops of the long loops may be sheared off to formcut pile tufts substantially equal to orgreater than the height of the uncut short pile,loops.,

Having described myinvention I'claim: 1. In the simultaneous manufacture of a plurality of frieze pile fabrics. having long and short loops on a double shuttle loom having a-pair of sets of shedded p le gauges extending warpwise-of the loom, the steps which comprise shedding the sets of gauges together ground wefts in the respective fabrics. shedding the sets and simultaneously laying picks outside the gauges forming of gauges'apart and laying simultaneously picks between the wefts forming face wefts for supporting free short loops on the respective fabrics, looping pile warp threads secured. to the respective grounds over the respective wefts between the gauges, shedding the gauges together and laying simultaneously a pair of picks outside the gauges, one of which forms a ground weft in one of the fabrics and the other of which is laid between the gauges and a ground of the other fabric to form a face weft for a free long pile loop on one of the fabrics in which the complementary pick forms a ground weft looping a warp thread from the fabric more removed therefrom about said face weft and securing said pile warp into the fabric of its origin.

2. In the manufacture simultaneously of a plurality of frieze pile fabrics having superposed grounds on a double shuttle loom having a plurality of gauges extending warpwise of the loom, the steps which include laying a row of weft above the-gauges and a row of wefts below the gauges, and two rows of wefts between the gauges, interlacing ground warps with some but not all of the row of wefts above the gauges, in-

terlacing ground warps with some but not all of the row of wefts below the gauges, looping warp threads secured to the upper ground over some of the wefts between the gauges and over the remaining wefts below the gauges which are not interlaced with the bottom ground warps and looping pile warp threads secured to the bottom ground over some of the wefts between the gauges and over the remaining wefts above the gauges which are not interlaced with the top ground warps.

3. In the manufacture simultaneously of two frieze pile fabrics face to face on a double shuttle loom having two sets of superposed shedded gauges between the grounds of the fabrics and extending warpwise of the loom, the steps which include setting both gauges to their horizontal positions, shedding the ground warps and pile warps and simultaneously inserting wefts in the sheds formed thereby so that the pile warps lie at-the back of their respective fabrics, then closing the sheds and beating up the wefts into position, forming a second set of shedsand simultaneously inserting wefts so that some of the pile threads of one of the fabrics are supported by a weft over the gauges more remote from the back of such fabric and the other weft is inserted in the ground of the same fabric to which the said pile is bound, closing the sheds and beating up the second set of wefts into position, forming a third shed and moving the gauges in opposite directions from each other, simultaneously inserting a third set of wefts between the gauges so as to act as a support for other pile warps from both fabrics, closing such shed and beating up the third set of wefts into position, forming a fourth shed and returning the gauges to their horizontal position, then simultaneously inserting a set of wefts so that the remaining pile threads are supported only by a weft over the gauges more remote from the back of the fabric to which the pile threads are bound, the other weft being inserted in the ground of said fabric, closing the shed, and beating up the fourth set of wefts preparatory to repeating thecycle.

4. In the simultaneous manufacture of selfseparating frieze fabrics having pile loops of two different heights face to face on a double shuttle loomhaving two sets of shedable warpwise e'xtending gauges spaced between the grounds of 

